Evaluation of Dressing Conditions and Grinding Characteristics Considering the Differences in Dresser Tip Shapes

Abstract

Dressing a grinding wheel before machining is a crucial step in grinding processes, as it restores the cutting ability of dulled or flattened wheels. The condition of the grinding wheel surface is significantly altered depending on the dressing conditions, thereby affecting grinding resistance, surface roughness, and grinding wheel wear. Therefore, applying the appropriate dressing to the grinding wheel surface is essential for achieving good machining performance. Moreover, the grinding wheel surface condition is influenced by both the dressing conditions and dresser tip shape. Even with the same dresser, the tip shape gradually changes owing to dresser wear, necessitating the selection of dressing conditions that consider both the dresser tip shape and its wear state. In this study, two types of single-point dressers with different wear states and two types of prismatic dressers with different sizes are used for dressing. The objective of this study is to clarify the effects of dresser tip shape and dressing conditions on grinding characteristics and grinding wheel wear. The results showed that these effects could be evaluated by defining the relationship between the dresser tip shape and dressing lead as the tip overlap ratio and overlap ratio. Furthermore, by selecting dressing conditions that consider the dresser tip shape, the desired grinding characteristics and grinding wheel wear could be achieved regardless of the dresser type or shape.